Sole for sports shoes

ABSTRACT

Described are methods for manufacturing a sole, in particular, a sole for a sports shoe, comprising providing at least one first sole element ( 110; 210 ) and at least one second sole element ( 130; 230 ); and injecting at least one second sole element ( 130; 230 ) through the at least one first sole element ( 110; 210 ). Also described are methods for manufacturing a shoe, in particular a sport shoe, wherein the method comprising: providing a flexible sock element ( 350; 450; 521 ) and at least one sole element ( 380; 480; 570 ); injecting the at least one sole element ( 380; 480; 570 ) on the flexible sock element ( 350; 450; 521 ), such that the at least one sole element ( 380; 480; 570 ) comprises a stiffening element ( 385; 485; 575 ) below the arch of the foot.

CROSS REFERENCE TO RELATED APPLICATION

This application is related to and claims priority benefits from GermanPatent Application No. DE 10 2015 204 268.5, filed on Mar. 10, 2015,entitled “Sole for sports shoes, as well as their manufacturing” (“the'268.5 application”). The '268.5 application is hereby incorporatedherein in its entirety by this reference.

FIELD OF THE INVENTION

The present invention relates to a sole, in particular, a sole for asports shoe, as well as a method for manufacturing said sole. Moreover,the invention relates to a shoe, in particular, a sports shoe, as wellas a method for manufacturing said shoe.

BACKGROUND

Shoes, in particular, sports shoes, generally have a sole and a shoeupper. The sole of the shoe protects the foot from injuries, which may,for example, result from stepping on sharp objects. The sole may alsoincrease the traction for the wearer of the shoe. The shoe upper holdsthe foot within the shoe and on the sole. Further, the shoe upper mayprovide stability to the foot, for example, by preventing the foot fromtwisting during fast movements. Moreover, the shoe upper may protect thefoot from outside influences, such as water and dirt.

Shoe uppers and shoe soles have different requirements. Therefore, asole is usually manufactured from a different material than a shoeupper, and the sole is attached to the shoe upper after manufacturing.Soles may, for example, be stitched, glued or nailed to shoe uppers.Also, a sole or a shoe upper often have different requirements that haveto be met in different regions, thus the sole or the shoe upper may eachbe composed of several individual constituents.

Manufacturing methods for such multi-part shoes require that theindividual constituents of the shoes are, for example, punched or cut ina multitude of separate fabrication steps. This not only leads to alabor-intensive and complex manufacturing method, but also produces alarge amount of waste in the form of arising scraps. Moreover, theindividual constituents have to be connected to each other, for example,stitched or glued, and often must be connected manually. This adds tothe intensity and complexity of the labor. Furthermore, when gluing, forexample, often solvents are used, which are harmful to the environment.

EP 2 815 668 A1 discloses a method for manufacturing a shoe, in which asock-shaped base member is attached to a last portion. A molten resin issupplied and allowed to cure on the base member.

Various approaches are known for using injection molding formanufacturing a shoe.

DE 34 40 567 A1 discloses a sports shoe with an injected sole andinjected pins.

U.S. Pat. No. 4,447,967 discloses a shoe, which is manufactured byinjecting a plastic material onto a sock. In order to ensure a securebonding of the plastic material and the sock, the sock comprises a basepart formed of a less dense fabric, which is penetrated by mutuallyintersecting ribs of the plastic material.

However, the known approaches for injecting parts of shoes have severaldisadvantages regarding the stability of the shoe and, apart from that,technical implementations of the known approaches are difficult. In viewof this background, it is an object of the present invention to improvethe provision of shoes and soles by injection molding.

SUMMARY

The terms “invention,” “the invention,” “this invention” and “thepresent invention” used in this patent are intended to refer broadly toall of the subject matter of this patent and the patent claims below.Statements containing these terms should be understood not to limit thesubject matter described herein or to limit the meaning or scope of thepatent claims below. Embodiments of the invention covered by this patentare defined by the claims below, not this summary. This summary is ahigh-level overview of various embodiments of the invention andintroduces some of the concepts that are further described in theDetailed Description section below. This summary is not intended toidentify key or essential features of the claimed subject matter, nor isit intended to be used in isolation to determine the scope of theclaimed subject matter. The subject matter should be understood byreference to appropriate portions of the entire specification of thispatent, any or all drawings and each claim.

According to certain embodiments of the present invention, a method formanufacturing a sole comprises assembling at least one first soleelement with at least one second sole element by injecting the at leastone second sole element through the at least one first sole element.

In some embodiments, the at least one first sole element comprises aprofile element. The at least one first sole element, in certainembodiments, comprises an aperture.

In certain embodiments, the at least one second sole element comprisesat least one of the following synthetic materials: polyamide,polyether-block-amide, polyvinylchloride, polyurethane, andpolyvinylchloride.

The at least one first sole element, in some embodiments, is provided ata flexible sock element.

In some embodiments, the flexible sock element comprises a textile.

In certain embodiments, the at least one second sole element forms anoutsole element.

The method, in certain embodiments, further comprises a step ofinjecting a reinforcing element for the flexible sock element, whereinthe providing of the at least one first sole element at the flexiblesock element comprises a step of injecting or clipping the at least onefirst sole element onto the reinforcing element.

In some embodiments, the reinforcing element comprises a Shore-Ahardness of approximately 25 to 75. The at least one first sole element,in some embodiments, comprises a Shore-A hardness of approximately 55 to95 and the at least one second sole element comprises a Shore-A hardnessof approximately 70 to 90.

According to certain embodiments of the present invention, a sole ismanufactured by providing at least one first sole element and at leastone second sole element and injecting the at least one second soleelement through the at least one first sole element. A shoe, in certainembodiments, comprises the sole.

According to certain embodiments of the present invention, a method formanufacturing a shoe comprises providing a flexible sock element and atleast one sole element, and injecting the at least one sole element ontothe flexible sock element, such that the at least one sole elementcomprises a stiffening element located (at a region) below the arch ofthe foot.

In some embodiments, the stiffening element is aligned along alongitudinal direction of the shoe. The stiffening element, in certainembodiments, extends from a region below the heel to a region below themetatarsals.

In certain embodiments, the stiffening element comprises a Shore-Ahardness of approximately 25 to 65.

The flexible sock element, in some embodiments, is provided with aprotrusion, and the at least one sole element is injected such that theat least one sole element, at least in part, encompasses the protrusionto provide a form-fitting connection between the flexible sock elementand the at least one sole element.

In certain embodiments, the flexible sock element is provided with anindentation, and the at least one sole element is injected such that theat least one sole element, at least in part, penetrates into theindentation, to provide a form-fitting connection between the flexiblesock element and the at least one sole element.

In some embodiments, the method further comprises a step of providing asole plate element with an elevation at the flexible sock element, andthe at least one sole element is injected, such that the at least onesole element, at least in part, encompasses the elevation to provide aform-fitting connection between the flexible sock element and the atleast one sole element.

The method, in certain embodiments, further comprises a step ofproviding a sole plate element with a recess at the flexible sockelement, and the at least one sole element is injected, such that the atleast one sole element, at least in part, penetrates into the recess toprovide a form-fitting connection between the flexible sock element andthe at least one sole element.

According to certain embodiments of the present invention, a shoecomprises a flexible sock element and at least one sole element, whereinthe at least one sole element is injected onto the flexible sock elementand the at least one sole element comprises a stiffening element located(in a region) below the arch of the foot.

BRIEF DESCRIPTION OF THE DRAWINGS

In the following detailed description, embodiments of the invention aredescribed referring to the following figures:

FIG. 1 is a perspective view of a sole with profile elements, throughwhich a second sole element was injected, according to certainembodiments of the present invention.

FIG. 2 is a schematic diagram illustrating the injection of a secondsole element through profile elements.

FIG. 3 is a side elevation view of a shoe showing a flexible sockelement and an injected sole element having a stiffening element belowthe arch of the foot, according to certain embodiments of the presentinvention.

FIGS. 4A-C are perspective views of a shoe with a flexible sock elementand an injected sole element having a stiffening element below the archof the foot and studs, according to certain embodiments of the presentinvention.

FIG. 5 shows a method for fabricating a shoe with a flexible sockelement and a sole with profile element.

FIGS. 6A-C show the steps of applying a flexible sock element onto amulti-part fixation element.

FIGS. 7A-O show a method for fabricating a shoe with a flexible sockelement in an apparatus having a fixation element and a mechanism forinjection molding with a mold for injection molding comprising at leastthree parts.

BRIEF DESCRIPTION

The object of this invention is, at least in part, achieved by a methodfor manufacturing a sole, a sole, a method for fabricating a shoe, and ashoe.

According to some embodiments, a method for manufacturing a sole, inparticular, a sole for a sports shoe, comprises a step of providing atleast one first sole element and at least one second sole element, and astep of injecting the least one second sole element, for example, byinjection molding, spraying, additive manufacturing, 3-D printing, orany other suitable method, through the at least one first sole element.

Thus, a sole having several individual sole elements may be providedwith a durable connection between the individual sole elements. Byinjecting at least one part of the sole through at least one other partof the sole, a form-fitting connection between the individual soleelements may be achieved. After the injection, at least a part of thematerial of the second sole element may remain in the first soleelement, such that a complete, or at least a partial, form-fittingconnection is provided between the first sole element and the secondsole element. As a result, lateral forces may be absorbed. By injectingthe second sole element through the first sole element, lateral forcesbetween the first sole element and the second sole element may beabsorbed, in at least in three, or in all four lateral spatialdirections. In some embodiments, a full sole layer, for example, anoutsole, may be injected through the at least one first sole element. Atleast one sole element may also extend to, and/or into, an upper portionof a shoe.

The lifetime of a sole, after which the first and/or the second soleelement disengage from the sole, may be substantially improved by thedescribed embodiments. The described embodiments allow using differentmaterials for the individual sole elements. Due to the at least partialform-fitting connection, the sole has essentially the same lifetime asthat of soles made from a single material.

The at least one sole element may have a profile element. For example,the first sole element may be adapted as a profile element. By injectingthe second sole element through the profile element, an at least partialform-fitting connection between the profile element and the second soleelement may be achieved, which enables the profile element to resist thelarge forces that arise when the sole contacts the ground. At the sametime, tailored materials may be used for the profile element and thesecond sole element, which may, for example, form at least a part of anoutsole.

The profile element may have at least one stud. For example, the profileelement may be adapted as a stud. Large lateral forces, which, studs ofa soccer shoe are exposed to during fast turns, for example, may besafely absorbed by the at least partial form-fitting connection betweenthe profile element and the second sole element. Some embodiments of thepresent method also allow providing soles for studded shoes or cleatedshoes, such as soccer shoes, which are stable even under outdoorconditions, such as varying temperatures and wet conditions. In otherembodiments, the profile element may be provided as a pin, or a nub,etc.

The first sole element may have an aperture. The aperture may be atunnel-like through hole of the first sole element. The through hole mayextend from an upper side of the profile element to a lower side of theprofile element. After injecting the second sole element through thefirst sole element, this aperture may, at least in part, be filled bythe material of the second sole element, such that a particularly stableconnection between the profile element and the second sole element isformed.

The second sole element may comprise at least one of the followingsynthetic materials: polyamide, polyether, block-amide,polyvinylchloride, polyurethane, thermoplastic polyurethane (TPU). Thesematerials are particularly suited to, for example, provide an outsolewith desired properties. Also, additional injected elements, which aredescribed herein, may comprise at least one of said synthetic materials.

The first sole element may be provided at a flexible sock element. Forexample, the first sole element may be injected onto the flexible sockelement, or the first sole element may be clipped onto the flexible sockelement. Using TPU as a material for at least one sole element, forexample, the first and/or the second sole element, has the benefit thatthe sole element may be transparent. Thus, even after the injection of arelatively thick layer of TPU for at least one sole element, theflexible sock element remains visible from outside. Using polyamide forat least one sole element, up to a certain layer thickness, also has thebenefit that the sole element may be transparent or milky.

Injecting the second sole element through the first sole element mayprovide a connection between the second sole element and the flexiblesock element. In addition, the connection between the first sole elementand the flexible sock element may be improved. Thus, for example, acomplete sole may be applied onto the flexible sole element. Theflexible sock element may be configured as a sock, which covers thefoot, and may extend, for example, to the ankle or beyond the ankle. Thedescribed method allows the provision of a shoe with a stable multi-partsole, wherein the sole elements are injected onto the flexible sockelement. Thus, an additional attachment of a separately manufacturedsole to a shoe is not necessary. The described method may, in addition,be fully automated. For example, the flexible sock element may beprovided in an automated manufacturing process. The at least one soleelement may be provided at the flexible sock element in an additionalmanufacturing step.

The flexible sock element may comprise a textile. For example, theflexible sock element may comprise a knitted fabric. A knitted fabricallows cost effective automated manufacturing and may be provided withvarious material properties. For example, a round-knitted and/orflat-knitted and/or a tubular-knitted fabric may be used. The flexiblesock element may be fabricated as a single piece, or it may be composedof several elements, for example, a ground-engaging portion and an upperportion, which may be stitched or glued, for example.

The flexible sock element may comprise at least one of the followingmaterials: polyamide, polyester, cotton, leather, polyurethane. Forexample, yarns and/or fibers consisting of polyamide, polyester,polyurethane and/or cotton may be used. Leather, for example, genuineleather and/or synthetic leather, may also be used. The flexible sockelement may be fabricated from a single material. Optionally, theflexible sock element may be printed, coated, additionallyfunctionalized and/or optically designed by other mechanisms.Alternatively, or additionally, the properties of the flexible sockelement may be optimized, for example, by combining different materialsin different regions.

The second sole element may form an outsole element. According to someembodiments, the outsole may be fabricated in a single step, and may bepermanently connected to other sole elements, for example, profileelements. The connection between the outsole and the other sole elementswithstands the high loads, which occur at an outsole. The method mayhave an additional step of injecting a reinforcing element onto theflexible sock element. In addition to fabricating the at least one firstand second sole elements, in an additional manufacturing step, theflexible sock element may be reinforced as desired by the reinforcingelement. For example, a tensile strength and/or a bending resistance ofthe flexible sock element may be locally increased by the reinforcingelement. A shoe with a stable multi-part sole may thus be manufacturedin a fully automated manner. For example, the reinforcing element may beinjected into an upper portion of the flexible sock element, such thatthe flexible sock element is provided with predetermined properties of ashoe upper. The reinforcing element may have a heel cap, and/or thereinforcing element may be injected such that it forms a heel cap.

The provision of the first sole element at the flexible sock element mayinclude injecting or clipping the first sole element onto thereinforcing element. Injecting the second sole element through the firstsole element may provide a connection of the second sole element to thereinforcing element. In addition, the connection between the first soleelement and the reinforcing element may be improved.

The at least one second sole element may be injected such that it isarranged, at least in part, between the reinforcing element and thefirst sole element. This arrangement may achieve a high mechanicalstability of the multi-part sole and the reinforcing element.

The reinforcing element may be injected such that it extends to and/oronto an upper region of the flexible sock element. Thus, the upperregion of the flexible sock element may be provided with desiredproperties of a shoe upper. To this end, a softer, more stretchableand/or more flexible material may be used, which is desirable for asole. The reinforcing element may comprise at least one through hole,through which the material of a first and/or a second sole element maypenetrate. The penetration may contribute to achieving an improvedconnection between the reinforcing element and the flexible sockelement. In general, harder materials allow a better connection to theflexible sock element. The material of the reinforcing element may alsobe arranged at a sole portion of the flexible sock element. In otherembodiments, the reinforcing element may be arranged only at the upperregion of the flexible sock element.

The second sole element may be harder, more abrasion resistant, and/orstiffer than the reinforcing element. Thus, in a sole region, a higherhardness, abrasion resistance and/or stiffness may be provided than inan upper region.

The reinforcing element may have a Shore-A hardness of approximately 25to 75, in particular 50 to 70, 35 to 55 or 40 to 50. Thus, thereinforcing element may, for example, sufficiently reinforce the upperregion, but, at the same time, provide good wearing comfort. Moreover,material of this hardness range may still be connected in a sufficientlystable manner by injecting, for example, at the flexible sock element.

The first sole element may have a Shore-A hardness of approximately 55to 95, in particular 60 to 95 or 85 to 95. This hardness range is alsowell suited for profile elements, for example.

The second sole element may have a Shore-A hardness of approximately 60to 100, in particular 70 to 90, or 75 to 85. This hardness range is wellsuited for an outsole, and this hardness range enables a secureconnection of the second sole element to a first sole element and/or areinforcing element.

In some embodiments, expanded TPU is applied as a sole element on theflexible sock element, in particular, for manufacturing a running shoeor similar types of shoes. Applying a sole element of expanded TPU maybe carried out in a separate step, for example, after injecting areinforcing element on the flexible sock element. Such a sole elementmay, for example, form a sole layer. A connection between the soleelement of expanded TPU and a reinforcing element and/or other soleelements may be achieved by suitable connecting techniques, such asinfra-red welding, chemical connecting techniques or any other suitableconnecting technique.

In some embodiments, a sole, in particular, a sole for a sport shoe, isprovided. The sole comprises at least one first sole element and atleast one second sole element. The at least one second sole element isinjected through the at least one first sole element.

The sole may be manufactured according to any one of the describedmethods.

According to certain embodiments, a shoe is provided with any of thesoles described above.

In some embodiments, a method for manufacturing a shoe, in particular, asports shoe, comprises a step of providing of a flexible sock element,and a step of injecting at least one sole element onto the flexible sockelement, such that the at least one sole element has a stiffeningelement below the arch of the foot. The stiffening element may have aspecific geometry, for example, it may be designed in a rib-like manner.

The sturdiness of a sole element, which has been injected onto aflexible sock element, may be improved by injecting the sole elementsuch that it has a stiffening element below the arch of the foot. Thearrangement of the stiffening element below the arch of the foot, mayprovide a sole element that is sufficiently resistant to bending andtorsion, which may safely prevent breaking of the arch of the foot ortwisting of the ankle. The stiffening element is of particularimportance if a sole element comprising TPU is injected. Also, wheninjecting a sole element made of polyamide, a stiffening element is ofrelevance and, in particular, enables sole elements of low thickness tobe applied while still providing a sufficiently stable sole. Soleelements having a low thickness may be desirable because such soleelements may be more transparent.

The stiffening element may be aligned along a longitudinal direction ofthe shoe. This arrangement of the stiffening element provides support tothe arch of the foot along its full length. Moreover, this arrangementof the stiffening element may prevent twisting of the ankle despite fastand powerful lateral movements, which arise in sports shoes.

The stiffening element may extend from a region below the heel to aregion below the metatarsals. Such an elongate stiffening elementensures a sufficient stability in the entire rear region of the shoefrom the heel to the metatarsals, while allowing increased flexibilityin the toe region. The stiffening element may also extend along acentral region of the foot, below the arch of the foot.

The sole element may be injected such that it extends to and/or onto anupper region of the flexible sock element. When the sole element atleast partially encompasses the flexible sock element, an improvedconnection between the flexible sock element and the sole element may beachieved. In this manner, an upper region of the flexible sock elementmay be provided with desired properties. The sole element may have athickness in the upper region of the flexible sock element that is lowerthan a thickness in a sole portion of the flexible sock element.

The flexible sock element may be provided with a protrusion and/or anindentation. The sole element may be injected, such that it at leastpartially encompasses the protrusion and/or such that it at leastpartially penetrates into the indentation, such that a form-fittingconnection is provided. A form-fitting connection is created by areas ofthe protrusion and/or of the indentation at least partially lyingagainst the sole element. The stiffening element may also be provided inthis manner. In addition, lateral forces may be absorbed by the at leastpartial form fitting connection, such that a particularly stableconnection between the sole element and the flexible sock element iscreated. The longevity of the sole may thus be significantly increased.

The method may further comprise a step of applying the flexible sockelement onto a fixation element. The fixation element may be arranged toprovide the protrusion and/or the indentation of the flexible sockelement. For example, the flexible sock element may be pulled over thefixation element before the sole element is injected. The fixationelement may have an elevation, which creates a protrusion at theflexible sock element placed thereon. The fixation element may also havea recess, which creates an indentation in the flexible sock element. Apressure and/or mechanical fixation mechanism, such as a hook, may holda region of the flexible sock element in the recess, such that anindentation is created in the flexible sock element. In otherembodiments, the flexible sock element may be pushed into the recess ofthe pressure and/or mechanical fixation mechanism by the injectedmaterial of the sole element. In some embodiments, the fixationmechanism includes a mechanism for ensuring the correct positioning ofthe flexible sock element.

The flexible sock element may be provided such that the protrusionand/or the indentation of the flexible sock element is, at least inpart, pre-formed. For example, the flexible sock element may be providedin a folded manner and/or in a plurality of layers to provide aprotrusion and/or an indentation. Moreover, a protrusion and/or anindentation may be achieved by a combination of flat knitting andcircular knitting. By using a fixation mechanism having an elevationand/or an indentation, it may be insured that the protrusion and/or theindentation in the flexible sock element is correctly arranged duringthe injection of the sole element. Moreover, the elevation and/or recessof the fixation mechanism may further form the protrusion and/or theindentation of the flexible sock element, for example, by stretching thematerial of the flexible sock element.

The described method may also comprise a step of providing a sole plateelement at the flexible sock element for forming the protrusion and/orthe indentation of the flexible sock element. The sole plate elementmay, for example, be inserted into the flexible sock element, or may beplaced at an outer side of the flexible sock element. The sole plateelement may also be put on the fixation mechanism, and, subsequently,the flexible sock element may be pulled over the fixation mechanism andthe sole plate element. The sole plate element may have an elevationand/or a recess to provide a corresponding protrusion and/or acorresponding indentation at the flexible sock element.

The method may further comprise a step of providing a sole plate elementwith an elevation and/or a recess at the flexible sock element, whereinthe sole element is injected, such that it, at least in part,encompasses the elevation and/or penetrates into the recess to provide aform-fitting connection. Thus, a safe connection between the sole plateelement and the sole element may be ensured. Also, a stiffening elementmay be provided in this manner. The sole plate element may, for example,be glued and/or stitched to the flexible sock element. According tocertain embodiments, the sole element may be injected onto the flexiblesock element such that the sole plate element is fixed at the flexiblesock element.

The sole element may be configured as a reinforcing element for theflexible sock element, and the method may further comprise a step ofinjecting an outsole element onto the reinforcing element. Thereinforcing element may extend to and/or onto an upper region of theflexible sock element. In an upper region, a thickness of thereinforcing element may be reduced compared to a thickness of thereinforcing element in the sole region. By using a two-step injection ofa reinforcing element and an outsole element, the properties for theupper region and the sole region may be tailored, as needed,independently from each other.

The sole element may also be configured as an outsole element. Moreover,a reinforcing element may be injected onto the flexible sock elementprior to the injection of the outsole element. The reinforcing elementmay be configured such that it has a constant thickness in the soleregion. The reinforcing element may have at least one through hole, forexample, in the sole region around an indentation and/or a protrusion ofthe flexible sock element.

The outsole element may be harder, more abrasion resistant, and/orstiffer than the reinforcing element. The properties of the outsoleand/or of the upper region of the shoe may thus be tailored as needed.

The reinforcing element may comprise a Shore-A hardness of approximately25 to 65, in particular 35 to 55 or 40 to 50.

The reinforcing element may have at least one through hole. This mayhelp achieve an improved connection between the reinforcing element, theoptional outsole element and the flexible sock element.

The outsole element may comprise a Shore-A hardness of approximately 60to 100, in particular 70 to 90 or 75 to 85.

According to some embodiments, a shoe, in particular, a sports shoe,comprises a flexible sock element and at least one sole element, whichis injected onto the flexible sock element and has a stiffening elementbelow the arch of the foot.

The shoe may be manufactured according to any of the methods describedabove.

The flexible sock element, the sole element and the reinforcing element,may have additional properties.

According to a certain embodiments, an apparatus for manufacturing ashoe is provided. The apparatus has a fixation element for a flexiblesock element and a mechanism for injection molding arranged around thefixation element, which has a mold for injection molding comprising atleast three parts, such as a mold in which the cavity for the materialfor injection molding is formed by three or more parts of the mold wheninjection molding.

A three-part design (a design having three parts) enables molds forinjection molding to be provided in a more versatile manner becauseindividual parts of the three-part mold may be exchanged, as needed. Forexample, a flexible sock element may be provided with a plurality ofinjected elements without requiring a complete new mold for injectionmolding for each injected element. The flexible sock element on thefixation element may, for example, be fixed by two parts of themechanism for injection molding. For example, two parts of the mechanismfor injection molding may be arranged movably, with respect to eachother, such that the flexible sock element on the fixation element maybe clamped within the mechanism for injection molding by these twoparts. Thus, the third part of the mechanism for injection molding maybe quickly exchanged without having to position and fix the flexiblesock element again. For example, the third part may be designated forthe sole portion of the flexible sock element, such that the soleportion of the flexible sock element may be provided with differentelements by exchanging only this third part.

The mechanism for injection molding may have a first mold part, whichencompasses the fixation element at an area that is designated for asole of the shoe, in order to form a first mold for injection moldinghaving at least three parts. Thus, for example, a sole element with apredetermined shape may be injected onto the flexible sock element usingthe first mold part. The at least two additional parts of the mechanismfor injection molding may, for example, only ensure that an upper regionof the flexible sock element remains free from injected material duringinjection of the sole element. Alternatively, the additional parts ofthe mechanism for injection molding may be configured to shape the upperregion such that the sole element may, for example, extend to and/oronto the upper region. The first mold part may also ensure that, atleast in a partial region of the sole region, no material is injected.The at least two additional parts of the mechanism for injection moldingmay also be adapted for shaping, for example, a reinforcing element,which is not arranged in the sole portion of the flexible sock element.The first mold part may be designed to be multi-part (to have aplurality of parts).

The mechanism for injection molding may have a second mold part, whichencompasses the fixation element at an area that is designated for thesole of the shoe, instead of the first mold part, in order to form asecond mold for injection molding that has at least three parts. Thus,for example, a further sole element and/or a reinforcing element may beinjected using the second mold part. The second mold part may ensurethat when injecting a reinforcing element, for example, at least a partof the sole portion of the flexible sock element remains free frominjected material. The second mold part may, alternatively, oradditionally, be designed to shape the sole portion.

The mechanism for injection molding may have at least two lateral moldparts which are movable relative to each other, and laterally encompassthe fixation element. The lateral mold parts may determine the shape ofsole and/or reinforcing elements on the upper region of the flexiblesock element, for example. The at least two lateral mold parts may fixthe flexible sock element at the fixation element such that the positionof the flexible sock element is fixed in all three spatial directions.

The two lateral mold parts may be arranged in a movable manner relativeto the first mold part and/or to the second mold part. Thus, the lateralmold parts may be joined with the first mold part and/or second moldpart to form a first and/or second mold for injection molding,respectively, for example, in an automated manner.

The apparatus may also have a device for removing the fixation elementfrom the mechanism for injection molding. Thus, the fixation element andthe flexible sock element may be removed from the mechanism forinjection molding safely and without damaging the mold for injectionmolding. Also, a contamination of the mold for injection molding maythus be prevented.

The fixation element for the flexible sock element may be configured tobe multi-part. Thus, the fixation element may, for example, be adaptedto flexible sock elements corresponding to different shoe sizes. Also,arranging the flexible sock element around the fixation element may befacilitated.

The described apparatus may be configured such that one of the describedmethods may be carried out. In particular, the apparatus may beconfigured such that the described methods may be carried out in a fullyautomated manner.

According to some embodiments, a method for manufacturing a shoe, inparticular, a sports shoe, comprises a step of providing a syntheticupper material and a step of providing at least one profile element. Theat least one profile element is provided at the synthetic upper materialsuch that a sole element, for example an outsole element or an outsole,may be injected between the synthetic upper material and the at leastone profile element. The injecting of the sole element may be carriedout such that the sole element adheres to both of the synthetic uppermaterial and the at least one profile element at the same time. Thus,the at least one profile element may be connected with the syntheticupper material by the injecting of the sole element, without requiring aseparate manufacturing step. For example, by directly injecting anoutsole between the synthetic upper material and the studs, the studsare durably connected with the outsole, and the outsole is durablyconnected with the synthetic upper material. Thus, the need for anadditional fabrication step for manufacturing the shoe is eliminatedbecause connection devices such as adhesives, are not needed. A benefitof a shoe manufactured according to the described methods is that theshoe will have a particularly low weight. Moreover, the describedmethods enable automation of the manufacturing process.

The injecting may, for example, be carried out by injection molding. Theinjected material may, for example, comprise TPU. The synthetic uppermaterial may be placed on a fixation material. A production line mayhave a plurality of such fixation elements. Moreover, a mechanism forreceiving profile elements, in particular studs, may be provided. Atleast one profile element, such as studs or islands of studs, may beinserted in the at least one mechanism for receiving profile elements.The profile elements may be pre-manufactured from TPU, such as by asuitable injection molding method. The profile elements may haveprotrusions or indentations, which the injection molding material mayencompass, or, in which the injection molding material may extend into,in order to achieve an additional form-fitting connection between theinjected material and the at least one profile element. The samegenerally applies to the synthetic upper material. Protrusions and/orindentations may also be provided to achieve an additionally stabilizingform-fitting connection.

After the insertion of the synthetic upper material into the fixationelement and the insertion of the at least one profile element into theat least one mechanism for receiving profile elements, the fixationelement, together with the synthetic upper material, may be movedtowards the at least one profile element, until only a small gap remainsbetween the synthetic upper material and at least one profile element.The size of the gap may be adapted to the thickness of the sole elementto be injected. A sole element, such as an outsole, for example madefrom TPU, may be injected between the synthetic upper material and theat least one profile element.

In other embodiments, instead of the synthetic upper material, adifferent material may be used, and generally, a flexible sock elementmay be provided and used as explained above with reference to theflexible upper material. Moreover, some embodiments with a syntheticupper material and a flexible sock element, respectively, may becombined with aspects, which were described in the context of otherembodiments.

According to certain embodiments, a method for manufacturing a shoe, inparticular, a sport shoe, comprises a step of providing at least onefirst sole element of the shoe and at least one second sole element ofthe shoe is injected through the at least one first sole element of theshoe. The aspects described herein may also be used for fabricatingelements of a shoe, which do not necessarily need to be arranged at thesole.

DETAILED DESCRIPTION

The subject matter of embodiments of the present invention is describedhere with specificity to meet statutory requirements, but thisdescription is not necessarily intended to limit the scope of theclaims. The claimed subject matter may be embodied in other ways, mayinclude different elements or steps, and may be used in conjunction withother existing or future technologies. This description should not beinterpreted as implying any particular order or arrangement among orbetween various steps or elements except when the order of individualsteps or arrangement of elements is explicitly described.

Possible embodiments of the present invention will be described in thefollowing detailed description primarily with reference to soles forsport shoes and with reference to sport shoes, respectively. However, itis emphasized that the present invention is not limited to theseembodiments. Rather, it may also be applied to other types of soles orshoes, respectively.

Moreover, it is noted that only individual embodiments of the inventionmay be further explained in the following. The person skilled in the artreadily recognizes that the implementation details described withreference to these specific embodiments may be modified or combineddifferently with each other within the scope of the invention, and thatindividual features may also be omitted as far as these seem to beoptional. In order to avoid repetitions, in particular reference is madeto the explanations in the above paragraphs, which also apply to thefollowing detailed description.

FIG. 1 shows a shoe with a sole 100, according to certain embodiments.The sole 100 has a plurality of first sole elements in the form ofprofile elements, such as studs 110. Each profile element 110 maycomprise an opening 120. The profile elements 110 optionally arearranged on an element 140, which may be manufactured in a single piecetogether with studs 110, for example by injection or additivemanufacturing. Element 140 may, however, also be fabricated separatelyand/or from a different material. Element 140 may, for example, beadapted as a reinforcing element made from TPU and/or may form amid-sole element. Element 140 may be adapted to be multi-part.

Through the openings 120 of the profile elements 110, a second soleelement in the form of an outsole element 130 is injected, and may be,for example, made from polyamide. Outsole element 130 is injectedthrough all openings 120. In other embodiments, an outsole element 130and/or other sole elements may only be injected through a subset ofprofile elements 110 and/or subset of openings 120. In otherembodiments, only some of the profile elements 110 may comprise anopening 120 and/or some of the profile elements 110 may comprise morethan one opening 120.

Outsole element 130 has a plurality of through holes in the forefootregion and one through hole in the heel region, through which element140 may be seen. In other embodiments, other through holes may beprovided. Outsole element 130 may also be adapted as a continuousoutsole. Outsole element 130 may be a 3-dimensional structure. Forexample, outsole element 130 may have a higher thickness below theprofile elements 110 than between the profile elements 110, as may beseen in the heel region in FIG. 1.

The partial arrangement of the material of outsole 130 in the openings120 of profile elements 110 allows, as explained above, a particularlystable mechanical connection between the outsole 130 and the profileelements 110. In addition, the at least partial sandwich-likearrangement of the material of outsole element 130 between profileelements 110 and element 140 contributes to the stability of the sole100. In some embodiments, sole 100 may be fabricated separately. Inother embodiments, sole 100 may be fabricated directly on a shoe upperor a flexible sock element. It is emphasized that element 140 isoptional. Profile elements 110 may be provided at a lower side of a shoeupper or a flexible sock element. Outsole element 130 may be injectedthrough at least one of profile elements 110 such that sole 100 isdirectly provided at the lower side and such that a separate connectionof sole 100 to the lower side is not necessary. In other embodiments,instead of outsole element 130, a different sole element is injectedthrough at least one of profile elements 110.

FIG. 2 shows a schematic illustration of the injection of a second soleelement 230 through first sole elements, which are adapted as studs 210,for fabricating a shoe 200. A flexible sock element 250 is arrangedabove a fixation element 260. A reinforcing element 240 is arranged onthe flexible sock element 250. The reinforcing element 240 may, forexample, be injected onto flexible sock element 250 in a firstfabrication step. The reinforcing element 240 extends along the soleportion of the flexible sock element 250 and to and/or onto the upperregion thereof. The reinforcing element 240 may form a heel cap. In someembodiments, the reinforcing element 240 may fully extend aroundflexible sock element 250. The reinforcing element 240 may achieve, forexample, a desired stiffening of the upper region. A thickness of thereinforcing element 240 may be lower in the upper region compared to athickness in the sole region. Moreover, it may be constant in the upperregion. In the sole region, the reinforcing element may be thickened inregions in which first sole elements, for example studs 210, areprovided. Thus, the first sole elements may be pre-formed by thereinforcing element 240.

First sole elements, for example studs 210, are provided on thereinforcing element 240. Studs 210 may, for example, be injected ontothe reinforcing element 240 in an additional fabrication step.Alternatively, studs 210 may be clipped onto reinforcing element 240. Tothis end, a corresponding notch may be provided in the reinforcingelement 240. It is not necessary to stably attach studs 210 at thispoint. For example, it is sufficient, if the studs 210 are connected viaa mandrel 215, or any other thin element, to the reinforcing element240. The mandrel 215 may serve as a spacer between the studs 210 and thereinforcing element 240. It is also possible to arrange only the firstsole elements, for example the studs 210, at the reinforcing element 240or, in case the optional reinforcing element 240 is not present, at theflexible sock element 250, without realizing a connection. For example,the first sole elements, such as studs 210, may be held only at, orclose to, the reinforcing element 240 and/or at the flexible sockelement 250.

The fixation element 260, the flexible sock element 250 arrangedthereupon with its reinforcing element 240, and the studs 210 are fixedwithin a mechanism for injection molding having a mold for injectionmolding. The mold for injection molding has three parts. It comprisestwo lateral mold parts 271, 272, as well as a top mold part 280.Optionally, the mold for injection molding has a bottom part 290. Thetop mold part 280 is adapted such that the material for the second soleelement 230 may flow to the openings 220 of studs 210 via at least onechannel. The channels may be adapted such that the material streamsinwards in the direction of the openings 220 in a way to avoidturbulences during influx. By arranging the material of the second soleelement 230 at least partially within studs 210, and between studs 210and reinforcing element 230, and flexible sock element 250,respectively, a stable connection may be provided, as explained above.

In a central region of the sole, the second sole element 230 may have astiffening element, which is arranged below the arch of the foot. Thestiffening element may be adapted such that it tapers in the region ofthe heel and in the region of the metatarsals and transitions into aflat region of the second sole element 230. FIG. 2 shows a cross sectionof such a tapered stiffening element. Full views of possible stiffeningelements are shown in FIGS. 3 and 4.

The lateral mold parts 271, 272 and top mold part 280 shape the secondsole element 230. The second sole element 230 may be adapted as anoutsole element. The outsole element, according to FIG. 2, extends toand/or into the upper region of flexible sock element 250. Thisextension allows an improved connection of the outsole element to thereinforcing element 240 or the flexible sock element 250, respectively.This extensions also allows providing desired properties to a regionaround the sole region. For example, the outsole element may comprise amaterial, which has a greater hardness, a greater abrasion resistanceand/or a greater stiffness than the material of reinforcing element 240.The optional bottom part 290 of the mechanism for injection molding maydetermine a boundary surface of the outsole element 230. Alternatively,or additionally, the boundary surface may also be provided by an edge ofthe lateral mold parts 271, 272. In other embodiments, second soleelement 230 may be adapted as a different element, for example, anintermediate sole element or a midsole element.

FIG. 3 shows a shoe 300, according to certain embodiments, with aflexible sock element 350 adapted as a sock. The flexible sock element350 has an upper region 352 and a sole portion 353. These two portionsmay each be fabricated to be one-piece (e.g. monolithic). They may bestitched to each other or glued to each other. In other embodiments,different and/or further portions may be provided. Flexible sock element350 may also be fabricated to be one-piece, and may, for example, beknitted. Flexible sock element 350 optionally has a seam 351. At thelower side of sole portion 353, a protrusion 355 may be provided. Theprotrusion 355 may, for example, be fabricated by circular knitting in aone-piece sole portion 353. Protrusion 355 may also be fabricatedseparately and connected to flexible sock element 350, for example, bystitching. The flexible sock element 350 may, for example, beimpregnated and/or be otherwise optically and/or functionally modifiedby printing, or coating etc. In other embodiments, flexible sock element350 may be adapted as an incomplete sock and cover only a part of thesurface of the foot.

Shoe 300 optionally has a sole plate 360, which may for example beformed from polyamide or TPU. The sole plate may, for example, befabricated by a suitable injection molding method or by a 3-D printingmethod.

In some embodiments, sole plate 360 is adapted to be arranged at thelower side of sole portion 353. For example, sole plate 360 may be gluedand/or stitched to the lower side of sole portion 353. Sole plate 360has an elevation 365, which is adapted such that protrusion 355 offlexible sock element 350 may be arranged therein. Sole plate 360 may,in other embodiments, be provided as a sole plate element, which coversonly a partial region of the lower side of sole portion 353, forexample, a forefoot region, such that, if needed, a pressure of thestuds may be distributed in a better way to the forefoot.

According to other embodiments, sole plate 360 is releasably attached ata sole portion of a fixation element, as described above, such as alast. For example, soluble adhesives or pins may be used for attaching.To connect with sole portion 353 of flexible sock element 350, soleplate 360 may have a hot-melt coating at its outer side facing away fromthe fixation element. After releasably attaching sole plate 360 onto thefixation element, flexible sock element 350 is pulled over the fixationelement and sole plate 360. Therein, sole plate 360 is arranged insidesole portion 353 of flexible sock element 350. When subsequentlyinjecting at least one of the sole elements onto flexible sock element350, sole plate 360 may be permanently connected with flexible sockelement 350 via the hot-melt coating. If needed, a removable insole maybe arranged above the sole plate 360 inside flexible sock element 350.

In some embodiments, sole plate 360 is exchangeably inserted intoflexible sock element 350. The insertion of sole plate 360 is carriedout after injecting sole elements on an outer side of the flexible sockelement. The sole plate may have an additional layer of dampingmaterial.

Shoe 300 may have a reinforcing element 370. The reinforcing element 370may be injected onto flexible sock element 350 and optionally onto soleplate 360. The reinforcing element 370 may enable the upper region 352of the flexible sock element 350 to be provided with desired mechanicalproperties. For example, in a lower region of the upper region of theflexible sock element 350 (or around it), an increased stiffness andtensile strength may be provided. This region may extend further upwardsalong the upper region into the heel region and into the instep regionthan it extends into a midfoot region because an increased sturdinessmay be desirable in the heel and instep regions. The reinforcing element370 may ensure that shoe 300 provides sufficient traction and preventsslipping of the foot within the shoe. For example, reinforcing element370 may be arranged across the entire instep region of flexible sockelement 350. In other embodiments, reinforcing element 370 is onlyarranged in a region of the forefoot adjacent to the sole. Reinforcingelement 370 may include through holes 371, which may selectively controlthe local material density. Thus, varying degrees of stiffness andtensile strength may be achieved. Moreover, reinforcing element 370 mayalso provide increased friction when contacting a ball, such as a soccerball. If reinforcing element 370 also extends onto sole plate 360, thelatter may be fixed to shoe 300 by the reinforcing element 370, withoutrequiring gluing and/or stitching of sole plate 360. Reinforcing element370 may, independently of the optional sole plate 360, extend onto soleportion 353 of flexible sole element 350.

Shoe 300 has a sole element 380. Sole element 380 may be adapted as anoutsole element. Sole element 380 may be injected onto sole portion 353of flexible sock element 350, onto an optional sole plate element 360arranged thereupon, and optionally onto reinforcing element 370. Forexample, sole element 380 may overlap reinforcing element 370 in aregion 386 of sole element 380 or in a region 376 of reinforcing element370, respectively, which are arranged along the edge of sole portion353. In other embodiments, different overlapping regions may beprovided. Sole element 380 has a stiffening element 385. Stiffeningelement 385 may ensure a sufficient stability of the sole of shoe 300.Sole element 380 may be injected such that it at least partiallyencompasses protrusion 355 and/or optional elevation 365, thus,providing stiffening element 385. Additionally, a form-fittingconnection between sole element 380 and flexible sock element 350 and/oroptional sole plate element 360 may thus be provided.

Sole element 380 may have through holes 381. In other embodiments, soleelement 380 may be arranged continuously and/or fully cover sole portion353. Sole element 380 optionally comprises profile elements 382, whichmay be adapted as nubs. In other embodiments, studs may also beprovided. Sole element 380 may overlap reinforcing element 370.

FIGS. 4A-B show some embodiments of a shoe 400 with a flexible sockelement 450. FIG. 4A shows a medial view of shoe 400. Flexible sockelement 450 may be adapted as a sock with a seam around an ankle region.Flexible sock element 450 may be optically designed or functionalized,as desired.

An injected reinforcing element 470 may be placed at the flexible sockelement 450. Reinforcing element 470 may at least partially be arrangedat a sole portion of flexible sock element 450. It may fully extendaround a sole portion of flexible sock element 450. Alternatively,reinforcing element 470 may be arranged only at a region along an edgeof the sole portion. Reinforcing element 470 may also extend onto anupper region of flexible sock element 450. Reinforcing element 470 mayhave a heel region. Reinforcing element 470 may optionally have aplurality of through holes 471 and/or nubs 472 and/or grooves 473.

Moreover, an injected sole element 480 may be placed onto flexible sockelement 450. Sole element 480 may be injected after injection ofreinforcing element 470, and sole element 480 may overlap withreinforcing element 470. Sole element 480 may be arranged in a soleportion of flexible sock element 450. Sole element 480 may, in addition,extend to and/or into the upper region of the sock element and may havea heel region. The heel region of sole element 480 may, fully orpartially, overlap the heel region of reinforcing element 470. Moreover,sole element 480 may fully or partially overlap reinforcing element 470in a region of the sole portion of flexible sock element 450, forexample, in a region along the edge of the sole portion. Sole element480 may have profile elements, such as nubs 482 and/or studs, etc.

Shoe 400 may have profile elements, such as studs 410. Studs 410 may beinjected onto the shoe. For example, studs 410 may be injected onto soleelement 480. Optionally, studs 410 may also be injected onto reinforcingelement 470 and/or flexible sock element 450. Sole element 480 may beinjected through studs 410. Alternatively, it is also possible to insertthe studs 410 into a mold and to inject the sole element 480 and/or thereinforcing element 470 between the studs 410 and the flexible sockelement 450.

FIG. 4B shows a medial bottom view of shoe 400. As shown in FIG. 4B, theshoe 400 may have through holes 481, nubs 482 and grooves 483 on thesole element 480 in addition to the through holes 471, nubs 472 andgrooves 473 of the reinforcing element 470. Moreover, the sole element480 has a stiffening element 485, which is arranged below the arch ofthe foot. Stiffening element 485 extends from below a rear region of theheel until below a region of the metatarsals. The stiffening element 485is aligned along a longitudinal direction of the shoe 400. The throughholes 481 and 471 of the sole element 480 and/or of the reinforcingelement 470, respectively, may influence the venting properties of shoe400. In particular, they may be adjusted to each other, such that awaterproof shoe 400 is provided. In some embodiments, sole element 480and/or reinforcing element 470 are provided without through holes 481and 471, respectively. Optionally, shoe 400 may also have at least onesole plate element, which is provided within the flexible sock element450 and/or outside at the lower side of the sole portion of the flexiblesock element 450.

Optionally, local injection ports 401 are provided in the mold forinjection molding for injecting the sole element 480 and/or thereinforcing element 470. Local injection ports 401 may be provided atthe positions of nubs 482 and 472, respectively, as shown in FIG. 4C.Thus, the injection occurs into larger cavities, such that turbulencesin the injection stream may be reduced, and a more even injection aswell as improved injection quality are enabled.

FIG. 5 shows a method for fabricating a shoe with a flexible sockelement and a sole with profile elements, having steps 1-11. The personskilled in the art readily recognizes that the individual steps are onlyexemplary and that individual steps may be omitted and/or the steps maybe carried out in different orders. Step 1 shows a step of printing ontoa flexible starting material 515 using a printer 510. Thus, the startingmaterial 515 may be optically designed and/or functionalized. Thestarting material may, alternatively, or additionally, also be coated orflock coated, etc. The starting material may be a sheet material.

Step 2 shows a cutting of portion 520 for a flexible sock element 521from the processed starting material 515. When using a sheet material asstarting material 515, a multitude of portions 520 may be cut out in acontinuous manufacturing process. The cutting out may, for example, becarried out by laser cutting. Alternatively, the portion 520 forflexible sock element 521 may also be die cut.

Step 3 shows a closing of the portion 520. The closing may be carriedout automatically by a robot arm 530, or the closing may be carried outsemi-automatically. By closing the portion 520, which may be fabricatedto be flat, a flexible sock element 521 is provided, which encompassesthe foot. The flexible sock element 521, which is shown in step 4, isapplied onto a fixation element, for example, pulled over a last.

In an injection molding step, a reinforcing element 550 is injected ontothe flexible sock element 521 as shown in step 5. The reinforcingelement 550 covers the sole portion of the flexible sock element 521 andextends to and/or onto the upper region of the sock element 521. Thereinforcing element 550 may be arranged continuously, i.e. withoutthrough holes. The reinforcing element 550 may fully cover the upperregion of flexible sock element 521 to form the upper of the final shoe(cf. step 8). The reinforcing element 550 may have thickenings 551 atthe sole portion of the flexible sock element 521. The thickenings 551may be arranged in regions, in which profile elements are to be placedat the shoe, as explained above with reference to FIG. 2.

In step 6, studs 560 are injected onto thickenings 551. In furtherembodiments, different and/or further profile elements may be provided.In particular, profile elements may also be injected without thickenings551. In other embodiments, the profile elements may be clipped on, orthey may be placed only at the reinforcing element 550.

In step 7, a sole element 570 is injected onto the reinforcing element550. The sole element 570 may be injected through at least one of theprofile elements 560, as, for example, explained above with reference toFIG. 2. The sole element 570 may have a stiffening element 575 below thearch of the foot. The stiffening element 575 may, for example, beprovided by injection in or around a recess and/or an elevation,respectively, on the reinforcing element 551, which may be provided asexplained above. The sole element 570 may also extend to and/or into theupper region of flexible sock element 521. For example, the sole element570 may be arranged in the heel region, in order to further strengthenthe shoe. Optionally, the sole element 570 may extend around the footaround a lower region of the upper region. The sole element 570 may bearranged as an outsole element or a complete outsole. Alternatively, anoutsole element or an outsole may be attached to sole element 570, forexample, by pressing or gluing.

Steps 8 and 9 relate to the provision of a laced fastening on the shoe.In step 8, a part 580 of the upper region of the flexible sock element521, around which the laced fastening is to be provided, is cut out.

This may be carried out by laser cutting or die cutting, etc. In step 9,holes 591 for the laces are created in the flexible sock element 521,for example, by die cutting. Moreover, a tongue 590 may be attached tothe flexible sock element 521, such as by stitching.

In step 10, a removable insole 593 is inserted into the shoe. The insole593 may, for example, have a lining. Moreover, insole 593 may have asole portion, in order to provide a further improved foot bed.Optionally, lacings may be inserted into holes 591.

In step 11, a right shoe and a left shoe are packed by a casing 599.

Steps 1-11 may be carried out in a fully automated manner. For example,they may be part of an on demand fabrication process, in which a pair ofshoes or a shoe is fabricated subsequent to an order and/or in acustomized manner. The fabrication process may be carried out in anautomated manner in a factory, and the shoes may be shippedsubsequently. The fabrication process may, however, also be carried outin a sporting goods store and/or in a shoe store. Due to the automatedfabrication, fast and individual manufacturing directly following thedemand of a customer is enabled. According to at least one of steps1-11, as described above, for example a business model regarding ondemand order/fabrication may be established.

FIGS. 6A-C show the application of a flexible sock element 650 onto amulti-part fixation element 660. FIG. 6A shows a two-part fixationelement 606D, which comprises a last. The fixation element 660 has aheel portion 661 and a toe and instep portion 662, respectively, whichform the last. These two portions may be fitted into each other and outof each other, respectively. Toe and instep portions 662 havingdifferent sizes may be provided, in order to adapt the size of the lastto the size of the respective flexible sock element 650, which has to beprocessed. The instep portion 662 and optionally the heel portion 661may jointly comprise a bulge 665 at the side, which is designated forthe sole portion of the flexible sock element 650. The bulge 665 may bedesignated to provide a protrusion on the flexible sock element 650 orto be arranged in a protrusion of the flexible sock element 650.Alternatively, or additionally, the flexible sock element 650 or thefixation element 660 may have an indentation or recess, respectively.The heel portion may have an attachment portion 663, which may bearranged to be elongate. The attachment portion 663 may enable thefixation element to be inserted into a mechanism for injection moldingmanually or in an automated manner.

FIG. 6B shows a flexible sock element 650, which may be provided, forexample, as explained above with reference to FIG. 3. The flexible sockelement 650 may, in particular, have a protrusion 655. Prior to applyingthe flexible sock element 650 to the fixation element 660, an optionallyprovided portion 651 of the flexible sock element 650, which extendsbeyond the region of the ankle of the foot, may be folded.

FIG. 6C shows the flexible sock element 650 with folded portion 651 asit may be placed on the fixation element 660. The provision of thefixation element 660 as a multi-part element may facilitate theplacement of the flexible sock element 650 onto the fixation element660. Prior to placing the flexible sock element 650, a sole plateelement may be placed within flexible sock element 650. Prior to, orafter the placing, alternatively, or additionally, a sole plate elementmay be placed on an outer side of the flexible sock element 650. Atleast one of the sole plate elements and/or the fixation element mayenable a protrusion and/or an indentation to be provided and/orsupported at the flexible sock element 650, as explained above.

FIGS. 7A-N show a method for fabricating a shoe with a flexible sockelement in an apparatus having a fixation element and a mechanism forinjection molding with a mold for injection molding having at leastthree parts.

In FIG. 7A, an exemplary flexible sock element 650 (cf. FIG. 6A-C)placed on the exemplary fixation element 660 is inserted into a firstlateral mold for injection molding 710, which is illustrated in a crosssectional view. The lateral mold for injection molding 710 has severallateral mold parts, including a lateral front mold part 711 and alateral rear mold part 716 (not shown in FIG. 7A; cf. for example FIG.7B). Moreover, the lateral mold for injection molding 710 also has topand bottom lateral mold parts 712 and 713, respectively, which are shownon the left side of FIG. 7A, and a top lateral mold part 714, which isshown on the right side of FIG. 7A. The lateral mold for injectionmolding 710 may have a further lateral bottom mold part, which may bearranged below the mold part 714, but is not shown in FIG. 7A. In otherembodiments, more or less or differently arranged lateral mold parts maybe provided. The lateral mold for injection molding 710 may optionallyhave a frame, below which the lateral mold parts are arranged. Thelateral mold parts 711, 712, 714 and 716 are each adapted to belaterally movable with respect to each other. Optionally, some of theselateral mold parts may be combined with other lateral mold parts, suchthat a lateral mold for injection molding may be provided in a modularmanner from a plurality of different lateral mold parts. At least one ofthe mold parts may then be used for different lateral molds forinjection molding.

FIG. 7B shows a top view of the lateral mold for injection molding 710with its mold parts 711, 712, 714, 716 and frame 718.

FIG. 7C shows a cross section of the lateral mold for injection molding710 with inserted fixation element 660 and flexible sock element 650.The fixation element may, for example, comprise a bulge 665, whicharranges itself in a protrusion 655 of the flexible sock element, orwhich provides the protrusion 655 of the flexible sock element,respectively. After correctly positioning and/or fixing the fixationelements 660 in the lateral mold for injection molding 710, for example,by its optional attachment portion 663, the lateral mold for injectionmolding 710 is closed. To this end, the lateral mold for injectionmolding 710 has a lateral device for closing 717. The lateral device forclosing 717 may, for example, have at least one bolt and/or at least onepiston, and a device for restoring, such as at least one spring.

The lateral device for closing 717 moves the lateral top mold parts 712and 714 towards each other. For example, lateral top mold parts 712 and714 are moved symmetrically toward each other. The lateral bottom moldparts 713 may be closed jointly with the lateral top mold parts 712 and714 or separately with their own device for closing. The front and rearlateral mold parts 711 and 716, respectively, may optionally be closedby their own corresponding device for closing. In FIG. 7C, the devicefor closing 717 is shown in an open state.

In FIG. 7D, the device for closing 717 is shown in a closed state.Moreover, as shown in FIG. 7D, the fixation elements 660 may be moved(in FIG. 7D downwards) such that the sole portion of the flexible sockelement 650 moves in a direction towards a center of the cavity, whichis formed by the lateral mold parts 711-716. This movement of thefixation element 660 may occur simultaneously with the movement of thelateral mold parts 711-716 or subsequently. To this end, a verticaldevice for closing 719 is provided, which has at least one piston orbolt and a device for restoring as the lateral device for closing 717.FIG. 7D shows that the lateral mold for injection molding 710 may have alever mechanism, which transforms the vertical movement of the devicefor closing 719 into a vertical movement of the attachment portion 663.During their downward movement, the two levers 719 a press onto thesliders 719 b, such that the sliders 719 b are pushed into the notches664 of the attachment portion 663. The sliders 719 b and the notches 664are adapted such that the attachment portion 663 moves downwards apredetermined amount, if the sliders 719 b are fully pressed into thenotches 664.

This position is shown in FIG. 7E. Thus, a fine positioning of thefixation element 660 within the lateral mold for injection molding 710is enabled. The sliders 719 b may have a device for restoring, such as aspring 719 c.

FIG. 7F shows the lateral mold for injection molding 710 within themechanism for injection molding 700. The mechanism for injection molding700 has a movable (for example rotatable) rack, and the lateral mold forinjection molding 710 is arranged within the rack. A plurality oflateral molds for injection molding 710 may be arranged within the rack,wherein the lateral molds may be separated by walls 705. Above the rack,at least one of the top mold parts 720 and 730 may be placed on acarrier 701. The top mold parts 720 and 730 may be placed in a hangingmanner. The lateral mold for injection molding 710 may be moved suchthat it is placed below a desired top mold part 720 or 730. The carrier701 may be moved downwardly onto the lateral mold for injection molding710 along at least one of the columns 702 such that by closing thelateral mold for injection molding 710 and the top mold part 720 or 730,a first mold for injection molding is provided.

FIG. 7G shows a bottom view of the first top mold part 720. The firsttop mold parts 720 may be adapted to be multi-part. For example, thefirst top mold part 720 may comprise a left heel part 722, a right heelpart 723 and a main part 721. The heel parts 722 and 723 may be arrangedto be laterally movable relative to the main part 721. In otherembodiments, additional and/or other parts of the first top mold part720 may be provided. The first top mold part 720 may be constructed in amodular manner from a plurality of parts, as explained above withreference to the lateral mold for injection molding 710. The first topmold part 720 may, alternatively, be provided as one-piece.

FIG. 7H shows the lateral mold for injection molding 710 and the firsttop mold part 720, which, in a closed state, jointly form a first moldfor injection molding. Via a lateral injection head 740 of the mechanismfor injections molding 700, a material may be injected into the firstmold for injection molding and onto the flexible sock element 650arranged therein. The injection head 740 may be placed into acorresponding opening of the top mold part. In other embodiments, theinjection into the first mold for injection molding may, for example,also occur from the top. Moreover, a plurality of injection heads mayalso be provided simultaneously. Optionally, further elements, such as asole plate element described with reference to FIG. 6, may be arrangedat the flexible sock element 650, before commencing the injection.

The injection process is schematically shown in FIG. 7I. The first moldfor injection molding comprises at least one channel 741 through whichthe material for an element 670 is injected onto the flexible sockelement 650. The material of the element 670 may be locally injected atdifferent positions. The material distributes itself within the cavityformed by the mold for injection molding during the injection.Optionally, the distribution may be supported, for example, byevacuating the cavity. The element 670 may be arranged as a reinforcingelement, such as the reinforcing element 370. The element 670 may,however, also be adapted as a sole element. The geometry of element 670is defined by the first mold for injection molding, which is formed bythe lateral mold for injection molding 710 and the first top mold part720. In some embodiments according to FIG. 7I, the top mold part servesthe purpose of sealing the flexible sock element 650 in a region, whichhas the sole portion and a part of the heel portion of the flexible sockelement 650. The material of the element 670 is injected into the cavitydefined by the lateral mold for injection molding. In other embodiments,the element 670 may extend across other regions of the flexible sockelement 650, such as its entire heel region and/or its sole portionand/or around its protrusion 655. The properties of the element 670 are,at least in part, determined by the respective material, which is usedfor its injection.

FIG. 7K shows a bottom view of a second top mold part 730. Generally,the second top mold part 730 may be configured similarly as the firsttop mold part 720 and may differ from the first top mold part 720 onlyby the design of the shaping portion of second mold part 730.

In some embodiments, the first top mold part 720 may be removed from thelateral mold for injection molding 720 after injecting the element 670.The lateral mold for injection molding 710 may then be moved such thatit is placed below the second top mold part 730. Finally, the second topmold part 730 may be moved towards the lateral mold for injectionmolding 710, such that the second top mold part 730 and the lateral moldfor injection molding 710 form a second mold for injection molding. Anadditional element 680 (cf. FIG. 7O) may be injected onto the flexiblesock element 650 by using the second mold for injection molding 730. Theshape of the injected additional element 680 is defined by the secondmold for injection molding. The additional element 680 may be adapted asan outsole element, such as outsole element 380. The material for theadditional element 680 may be injected into the second mold 730 forinjection molding using an injection head 750 from the top.Alternatively, the material may also be injected laterally, as explainedabove with reference to FIG. 7H. An injection head 750 for injectingfrom the top may be provided above the first top mold part 720 as wellas above the second top mold part 730. Moreover, an injection head 740for injecting from the side may be provided. Alternatively, it is alsopossible that only one injection head for lateral injection and/or forinjection from the top is provided at at least one of the top moldparts. Optionally, the injection head 740, 750 is adapted to be movableand/or rotatable.

FIG. 7M shows the mechanism for injection molding 700 with a device 760for removing the fixation element 660 from the mechanism for injectionmolding 700. The device 760 may be arranged as a bolt or piston, inorder to push the fixation element out of the lateral mold for injectionmolding 710 in a vertical direction towards the top, as shown in FIG.7M.

FIG. 7O shows a view of the flexible sock element 650 with an injectedfirst element 670 and an injected second element 680. A shoe 300, asexplained above with reference to FIG. 3, may be fabricated by thedescribed method and/or the described apparatus. Sole elements withstiffening element, first and second sole elements, profile elements,reinforcing elements, outsole elements, mid sole elements and/or otherelements, etc., as described with reference to FIG. 1-5 above, may beinjected onto flexible sock elements with or without a sole plateelement by correspondingly adapted first and second mold for injectionmolding and optionally further molds for injection molding.

In the following, further examples are described to facilitate theunderstanding of the invention:

A method for manufacturing a sole, in particular, for a sports shoe,wherein the method comprises:

providing at least one first sole element (110; 210) and at least onesecond sole element for the sole;

injecting the at least one second sole element (130; 230) through the atleast one first sole element (110; 210).

The method according to example 1, wherein the first sole element (110;210) comprises a profile element.

The method according to example 2, wherein the profile element (110;210) comprises at least one stud.

The method according to any of examples 1-3, wherein the first soleelement (110; 210) comprises an aperture (120; 220).

The method according to any of examples 1-4 wherein the second soleelement (130; 230) comprises at least one of the following syntheticmaterials: polyamide, polyether-block-amide, polyvinylchloride,polyurethane, and polyvinylchloride.

The method according to any of examples 1-5, wherein the first soleelement (110) is provided at a flexible sock element (250).

The method according to any of examples 1-6, wherein the flexible sockelement (250) comprises a textile, in particular a knitted fabric.

The method according to example 6 or example 7, wherein the flexiblesock element (250) comprises at least one of the following materials:polyamide, polyester, cotton, polyurethane, leather.

The method according to any of examples 1-8, wherein the second soleelement (130) forms an outsole element.

The method according to any of examples 1-9, further comprising the stepof injecting a reinforcing element (140; 240) for the flexible sockelement (250).

The method according to example 10, wherein the providing the first soleelement (110) at the flexible sock element (250) comprises a injectingor clipping of the first sole element (110; 210) on the reinforcingelement (140; 240).

The method according to example 10 or example 11, wherein the secondsole element (130; 230) is injected such that it is at least in partarranged between the reinforcing element (140, 240) and the first soleelement (110, 210).

The method according to any of examples 10-12, wherein the reinforcingelement (140; 240) is injected such that it extends until an upperregion of the flexible sock element (250).

The method according to any of examples 10-13, wherein the second soleelement (130; 230) is harder and/or more abrasion resistant and/orstiffer than the reinforcing element (140; 240).

The method according to any of examples 9-14, wherein the reinforcingelement (140; 240) comprises a Shore-A hardness of approximately 25 to75, in particular of 35 to 55, or 40 to 50.

The method according to any of examples 1-15, wherein the first soleelement (110; 210) comprises a Shore-A hardness of approximately 55 to95, in particular 60 to 95, or 85 to 95.

The method according to any of examples 1-16, wherein the second soleelement (130; 230) comprises a Shore-A hardness of approximately 60 to100, in particular 70 to 90 or 75 to 85.

A sole, in particular for a sports shoe, comprising:

-   -   at least one first sole element (110; 210) and at least one        second sole element (130; 230);

wherein the at least one second sole element (130; 230) is injectedthrough the at least one first sole element (110; 210).

The sole according to example 18, wherein the sole is manufacturedaccording to a method of any of claims 1-17.

A shoe with a sole according to example 18 or example 19.

A method for manufacturing a shoe, in particular a sport shoe, whereinthe method comprises:

providing a flexible sock element (350; 450; 521);

injecting at least one sole element (380; 480; 570) on the flexible sockelement (350; 450; 521), such that the at least one sole element (380;480; 570) comprises a stiffening element (385; 485; 575) below the archof the foot.

The method according to example 21, wherein the stiffening element (385;485; 575) is aligned along a longitudinal direction of the shoe.

The method according to example 21 or example 22, wherein the stiffeningelement (385; 485; 575) extends from below the heel until below themetatarsals.

The method according to any of examples 21-23, wherein the at least onesole element (380; 480; 570) is injected such that it extends until anupper region (352) of the flexible sock element (350; 450; 521).

The method according to any of examples 21-24, wherein the flexible sockelement (350) is provided with a protrusion (355) and/or an indentation,and a sole element (380) is injected such that it at least in partencompasses the protrusion (355) and/or it at least in part penetratesinto the indentation, to provide a form-fitting connection.

The method according to example 25, further comprising the step ofapplying the flexible sock element (350) onto a fixation element, whichis arranged to provide the protrusion (355) and/or the indentation ofthe flexible sock element (350).

The method according to example 25 or example 26, wherein the flexiblesock element (350) is provided such that the protrusion (355) and/or theindentation of the flexible sock element (350) is at least in partpre-formed.

The method according to any of examples 25-27, further comprising thestep of providing a sole plate element (360) at the flexible sockelement (350) for forming the protrusion (355) and/or the indentation ofthe flexible sock element (350).

The method according to any of examples 21-28, wherein the methodfurther comprises the step of providing a sole plate element (360) withan elevation (365) and/or a recess at the flexible sock element (350),and the at least one sole element (380) is injected, such that it atleast in part encompasses the elevation (365) and/or it at least in partpenetrates into the recess to provide a form-fitting connection.

The method according to any of examples 21-29, wherein the at least onesole element is configured as a reinforcing element for the flexiblesock element, and wherein the method further comprises the step ofinjecting an outsole element on the reinforcing element.

The method according to any of examples 21-29, wherein the sole element(380; 480; 570) is configured as outsole element.

The method according to example 31, further comprising: injecting of areinforcing element (370; 470; 550) on the flexible sock element (350;450; 521) before the injecting of the outsole element (380; 480; 570).

The method according to example 30 or example 32, wherein the outsoleelement (380; 480; 570) is harder and/or more abrasion-resistant and/orstiffer than the reinforcing element (370; 470; 550).

The method according to any of example 30, example 32, or example 33,wherein the stiffening element (370; 470; 550) comprises a Shore-Ahardness of approximately 25 to 65, in particular 35 to 55 or 40 to 50.

The method according to any of example 30, or any of examples 32-34,wherein the reinforcing element (370; 470) comprises at least onethrough hole (371; 471).

The method according to any of examples 30-35, wherein the outsoleelement (380; 480; 570) comprises a Shore-A hardness of approximately 60to 100, in particular 70 to 90 or 75 to 85.

A shoe, in particular sport shoe, comprising:

a flexible sock element (350; 450; 521);

at least one sole element (380; 480; 570), which is injected on theflexible sock element (350; 480; 521), and which comprises a stiffeningelement (385; 485; 575) below the arch of the foot.

The shoe according to example 37, manufactured with a method accordingto any of claims 21-36.

Different arrangements of the components depicted in the drawings ordescribed above, as well as components and steps not shown or describedare possible. Similarly, some features and sub-combinations are usefuland may be employed without reference to other features andsub-combinations. Embodiments of the invention have been described forillustrative and not restrictive purposes, and alternative embodimentswill become apparent to readers of this patent. Accordingly, the presentinvention is not limited to the embodiments described above or depictedin the drawings, and various embodiments and modifications may be madewithout departing from the scope of the claims below.

That which is claimed is:
 1. A method for manufacturing a solecomprising: providing a flexible sock element, injecting a reinforcingelement onto the flexible sock element, disposing at least one firstsole element by injecting or clipping the at least one first soleelement onto the reinforcing element, and assembling the at least onefirst sole element with at least one second sole element by injectingthe at least one second sole element through the at least one first soleelement such that the at least one second sole element penetrates the atleast one first sole element to provide a form-fitting connectionbetween the at least one first sole element and the second sole elementand the at least one second sole element extends to the reinforcingelement to secure the at least one first sole element to the reinforcingelement, wherein the at least one second sole element forms at least aportion of an outsole element, and wherein at least a part of the atleast one second sole element remains in the at least one first soleelement.
 2. The method according to claim 1, wherein the at least onefirst sole element comprises a profile element.
 3. The method accordingto claim 1, wherein the at least one first sole element comprises anaperture.
 4. The method according to claim 1 wherein the at least onesecond sole element comprises at least one of the following syntheticmaterials: polyamide, polyether-block-amide, polyvinylchloride,polyurethane, and polyvinylchloride.
 5. The method according to claim 1,wherein the flexible sock element comprises a textile.
 6. The methodaccording to claim 1, wherein the reinforcing element comprises aShore-A hardness of approximately 25 to
 75. 7. The method according toclaim 1, wherein the at least one first sole element comprises a Shore-Ahardness of approximately 55 to 95 and the at least one second soleelement comprises a Shore-A hardness of approximately 70 to
 90. 8. Themethod of claim 1, wherein the at least one second sole element injectedthrough the at least one first sole element extends beyond a bottomperiphery of the shoe and at least partially upward around at least aportion of an upper of the shoe.
 9. A method for manufacturing a shoecomprising: providing a flexible sock element having an upper region anda sole portion; injecting a reinforcing layer onto the sole portion ofthe flexible sock element; disposing at least one first sole element byinjecting or clipping the at least one first sole element onto thereinforcing layer; injecting at least one second sole element throughthe at least one first sole element such that the at least one secondsole element penetrates the at least one first sole element to provide aform-fitting connection between the at least one first sole element andthe reinforcing layer, and the at least one second sole element extendsto the reinforcing layer to secure the at least one first sole elementto the reinforcing layer; wherein the at least one second sole elementcomprises a stiffening element located at a region below an arch of afoot; and wherein the at least one second sole element forms at least aportion of an outsole element.
 10. The method according to claim 9,wherein the stiffening element is aligned along a longitudinal directionof the shoe.
 11. The method according to claim 9, wherein the stiffeningelement extends from a region below a heel to a region belowmetatarsals.
 12. The method according to claim 9, wherein the flexiblesock element is provided with a protrusion, and the at least one secondsole element is injected such that the at least one second sole element,at least in part, encompasses the protrusion to provide a form-fittingconnection between the flexible sock element and the at least one secondsole element.
 13. The method according to claim 9, wherein the flexiblesock element is provided with an indentation, and the at least onesecond sole element is injected such that the at least one second soleelement, at least in part, penetrates into the indentation, to provide aform-fitting connection between the flexible sock element and the atleast one second sole element.
 14. The method according to claim 9,wherein the method further comprises a step of providing a sole plateelement with an elevation at the flexible sock element, and the at leastone second sole element is injected, such that the at least one secondsole element, at least in part, encompasses the elevation to provide aform-fitting connection between the flexible sock element and the atleast one second sole element.
 15. The method according to claim 9,wherein the method further comprises a step of providing a sole plateelement with a recess at the flexible sock element, and the at least onesecond sole element is injected, such that the at least one second soleelement, at least in part, penetrates into the recess to provide aform-fitting connection between the flexible sock element and the atleast one second sole element.